U.S. patent number 10,174,714 [Application Number 15/217,568] was granted by the patent office on 2019-01-08 for apparatus and method for combined electrical and mechanical utilization of the energy of an expansion machine.
This patent grant is currently assigned to MAN Truck & Bus AG. The grantee listed for this patent is MAN TRUCK & BUS AG. Invention is credited to Gotz Freiherr Von Esebeck, Josef Klammer, Heribert Moller, Gottfried Raab, Stefan Robausch.
United States Patent |
10,174,714 |
Moller , et al. |
January 8, 2019 |
Apparatus and method for combined electrical and mechanical
utilization of the energy of an expansion machine
Abstract
An apparatus V and a method, preferably for a motor vehicle, in
particular a commercial vehicle. The apparatus V includes an
internal combustion engine, an expansion machine and a generator.
The expansion machine and the generator can be operatively
connected both to one another and in each case to the internal
combustion engine via a transmission, in order to make selective
electrical utilization and mechanical utilization of the energy of
the expansion machine possible.
Inventors: |
Moller; Heribert (Sachsen bei
Ansbach, DE), Raab; Gottfried (Perg, AT),
Klammer; Josef (Steyr, AT), Freiherr Von Esebeck;
Gotz (Blankenfelde-Mahlow, DE), Robausch; Stefan
(St. Ulrich bei Steyr, AT) |
Applicant: |
Name |
City |
State |
Country |
Type |
MAN TRUCK & BUS AG |
Munchen |
N/A |
DE |
|
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Assignee: |
MAN Truck & Bus AG (Munich,
DE)
|
Family
ID: |
56368749 |
Appl.
No.: |
15/217,568 |
Filed: |
July 22, 2016 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20170022933 A1 |
Jan 26, 2017 |
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Foreign Application Priority Data
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Jul 25, 2015 [DE] |
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10 2015 009 636 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60W
20/00 (20130101); F02G 5/02 (20130101); B60L
1/00 (20130101); B60K 6/485 (20130101); F01D
15/10 (20130101); B60W 20/40 (20130101); Y02T
10/62 (20130101); Y02T 10/6226 (20130101); Y10S
903/903 (20130101); Y02T 10/166 (20130101); Y02T
10/12 (20130101); B60Y 2400/206 (20130101) |
Current International
Class: |
F02G
5/02 (20060101); B60K 6/485 (20071001); F01D
15/10 (20060101); B60W 20/00 (20160101); B60L
1/00 (20060101); B60W 20/40 (20160101) |
Field of
Search: |
;60/614,616,618 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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10 2005 058 198 |
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Jun 2007 |
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DE |
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10 2007 026 264 |
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Dec 2008 |
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DE |
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10 2012 220 893 |
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May 2014 |
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DE |
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1243758 |
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Sep 2002 |
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EP |
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1574698 |
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Sep 2005 |
|
EP |
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2010-077901 |
|
Apr 2010 |
|
JP |
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20150075975 |
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Jul 2015 |
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KR |
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WO 2012/156175 |
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Nov 2012 |
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WO |
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WO 2015/197087 |
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Dec 2015 |
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WO |
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Other References
Search Report dated Nov. 22, 2016 which issued in the corresponding
European Patent Application No. 16001428.8. cited by
applicant.
|
Primary Examiner: Nguyen; Hoang
Attorney, Agent or Firm: Cozen O'Connor
Claims
What is claimed is:
1. An apparatus, comprising: an internal combustion engine; an
expansion machine; a generator, a transmission configured to
operatively connect the expansion machine and the generator to one
another and to the internal combustion engine via a transmission to
make selective electrical utilization and mechanical utilization of
energy of the expansion machine, wherein the generator is connected
to a system, the system comprising: an energy store that can be
charged by the generator for storing electrical energy; at least
one electrical consumer of a motor vehicle; a DC/DC converter
configured to supply the on-board power network of the motor
vehicle, and a control device configured to controlling the
generator.
2. The apparatus according to claim 1, wherein the expansion
machine is part of a waste heat utilization system that converts
waste heat of the internal combustion engine into utilizable energy
by a steam circuit.
3. The apparatus according to claim 1, wherein the expansion
machine is part of a waste heat utilization system that converts
waste heat of an engine backpressure sure brake system into
utilizable energy by a steam circuit.
4. The apparatus according to claim 1, wherein the expansion
machine and the generator are configured to be operatively
connected both to one another and in each case to a one of: a
crankshaft of the internal combustion engine and a power take-off
of the internal combustion engine via the transmission.
5. The apparatus according to claim 1, wherein the generator is
configured as one of: a) a motor/generator to operate selectively
as a generator or as a motor, and b) a pure generator.
6. The apparatus according to claim 1, wherein the system has at
least one of the following: a converter configured to supply an
on-board power network of the motor vehicle, and an electric motor,
via which energy from the energy store is converted into mechanical
energy and is made available to the internal combustion engine.
7. The apparatus according to claim 6, wherein the energy store
provides electrical energy for at least one of the on-board power
network and the at least one electrical consumer.
8. The apparatus according to claim 6, wherein the system is part
of at least one of an electrical and an electronic infrastructure
of a hybrid drive system that can be installed in the motor
vehicle.
9. The apparatus according to claim 1, wherein the generator is
operatively connected to the internal combustion engine in at least
one of a fixed manner and non-switchable manner.
10. The apparatus according to claim 1, wherein the transmission is
configured to at least one of: selectively establish and disconnect
the operative connection between the expansion machine and the
internal combustion engine, ensure a fixed operative connection
between the generator and the internal combustion engine, and
ensure a non-switchable operative connection between the generator
and the internal combustion engine.
11. The apparatus according to claim 6, wherein the apparatus is
configured to operate selectively in at least one of an expander
mode, a motor mode, and a generator mode.
12. The apparatus according to claim 11, wherein, in the expander
mode, a waste heat utilization system converts waste heat of the
internal combustion engine into utilizable energy, the expansion
machine generates mechanical energy from the utilizable energy, the
mechanical energy being made available to the internal combustion
engine via the transmission, and the generator generating
electrical energy from the utilizable energy, the electrical energy
being made available to the system.
13. The apparatus according to claim 11, wherein, in the generator
mode, the generator acts as a generator and the expansion machine
generates utilizable energy due to thermal inertia of a waste heat
utilization system despite lacking or low thermal input from the
internal combustion engine, and the generator generates electrical
energy from the utilizable energy of the expansion machine and from
mechanical energy of the internal combustion engine, the electrical
energy being made available to the system.
14. The apparatus according to claim 11, wherein, in the motor
mode, one of the generator acts as a motor and an electric motor of
the system acts as a motor, to convert electrical energy that comes
from an energy store into mechanical energy and makes the
mechanical energy available to the internal combustion engine via
the transmission.
15. The apparatus according to claim 11, wherein, during the motor
mode, the expansion machine at least one of does not generate any
mechanical energy, generates the mechanical energy, and at least
begins to generate the mechanical energy, and makes the mechanical
energy available to the internal combustion engine via the
transmission.
16. The apparatus according to claim 11, wherein, in the motor
mode, one of the generator acts as a motor and an electric motor of
the system acts as a motor, until an energy store is at least
largely emptied and the generator transfers into a generator
mode.
17. The apparatus according to claim 11, wherein, in a generator
mode, the generator acts as a generator, and the expansion machine
generates utilizable energy by thermal input from an engine
backpressure brake system, without thermal input from internal
engine combustion of the internal combustion engine, and the
utilizable energy is stored in an energy store and is made
available to the internal combustion engine in a subsequent motor
mode.
18. An operating method for an apparatus, having an internal
combustion engine, an expansion machine, a generator, a system to
which the generator is connected, and a transmission, comprising:
charging an energy store of the system by the generator for storing
electrical energy; supplying by a DC/DC converter an on-board power
network of the motor vehicle, controlling the generator by a
control device; and one of: operatively connecting the expansion
machine and the generator to one another and the internal
combustion engine via the transmission, and operatively connecting
at least one of the expansion machine and the generator to the
internal combustion engine via the transmission, and selective
utilization of electrical and mechanical energy of the expansion
machine.
19. A motor vehicle comprising: an apparatus comprising: an
internal combustion engine; an expansion machine; a generator, a
transmission configured to operatively connect the expansion
machine and the generator to one another and to the internal
combustion engine via a transmission to make selective electrical
utilization and mechanical utilization of energy of the expansion
machine, wherein the generator is connected to a system, the system
comprising: an energy store that can be charged by the generator
for storing electrical energy; at least one electrical consumer of
a motor vehicle; a DC/DC converter configured to supply the
on-board power network of the motor vehicle, and a control device
configured to controlling the generator.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus, preferably for a motor
vehicle, in particular for a commercial vehicle, for example a
lorry or an omnibus, that makes selective and therefore combined
electrical utilization and mechanical utilization of the energy of
an expansion machine of, for example, a mobile waste heat
utilization system possible and to a corresponding operating
method.
2. Description of the Related Art
In systems for waste heat utilization (Waste Heat Recovery=WHR) of
internal combustion engines, steam circuits, inter alia, are used.
Here, a circuit medium has to be brought to a high pressure level,
evaporated in an evaporator, and superheated. The steam is fed to
an expansion machine that converts the energy stored in the steam
into utilizable energy. Downstream of the expansion machine, the
steam is liquefied again and is fed to a feed pump.
It is known from practice to utilize the drive energy generated by
the expansion machine in two ways, namely either electrically or
mechanically.
Electrical Utilization:
Here, the expansion machine is coupled to a generator. The
generator converts the mechanical energy of the expansion machine
into electrical energy. The generated electrical energy is fed to
the internal combustion engine again via an electric motor and
therefore reduces the fuel consumption of the internal combustion
engine.
The use of the electrical energy generated to maintain the on-board
power network of a motor vehicle is therefore not expedient, since
the provided performance (for example, 5 kW in a main operating
range) lies above the required performance (for example, 2 kW).
Rather, a plurality of previously mechanically driven components
would have to be electrified, in order to increase the requirement
for electrical energy in the motor vehicle (for example, power
steering pump, coolant pump, various actuators). This results in
the problem that the energy from the WHR system is not permanently
available to its full extent. For example, the system requires some
minutes to heat up after cold starting, until the expansion machine
can be operated. At high temperatures, the energy that can be
generated of the expansion machine of the WHR system is also
reduced on account of limited performance of the vehicle cooling
system. In these cases, the high electrical energy requirement of
the motor vehicle would then have to be generated in a different
way, which can require additional generators on the internal
combustion engine.
However, electrical utilization of the expander energy permits an
attachment of the expansion machine independent of the engine with
regard to rotational speed and positioning. This leads to it not
being absolutely necessary for the expansion machine to be
installed on the internal combustion engine and to it being
possible for the expansion machine to be operated in an optimum
rotational speed range despite fluctuating internal combustion
engine rotational speeds. This advantage can compensate for or even
overcompensate for the disadvantage of the
expander-generator-electric motor-internal combustion engine
efficiency chain. A further advantage of the electrical utilization
consists in it being possible for the electrical energy to be
buffer-stored in combination with a battery. As a result, the WHR
system can also generate energy when the internal combustion engine
is, for example, in braking mode. The buffer-stored energy is then
made available to the internal combustion engine again via the
electric motor in a delayed manner.
Generators for electrical utilization of the expander energy will
usually operate with operating voltages of greater than 24 V on
account of the required power outputs. In principle, fast-rotating
turbomachines (steam turbines) are more suitable for coupling to a
generator than working chamber-forming machines (for example,
piston engines) at lower rotational speeds, since fast-rotating
generators are of more compact design.
Mechanical Utilization:
Here, the expansion machine is coupled mechanically to the internal
combustion engine via a transmission. It is an object of the
transmission to convert the rotational speed and to bridge spacings
between the expansion machine and the internal combustion engine,
and to connect and disconnect the expansion machine to/from the
internal combustion engine. The transmission can consist of a drive
in various embodiments (for example, friction wheel mechanism, spur
gear mechanism, planetary gear mechanism, chain drive, and/or belt
drive, etc.) or combinations thereof and an active or passive
switching element for connecting and disconnecting the expansion
machine and internal combustion engine (for example, clamping body
freewheel, switchable freewheel, electrically or hydraulically
actuated multiple disc clutch, etc.). The transmission feeds the
mechanical energy of the expansion machine to the internal
combustion engine again and therefore reduces the fuel consumption
of the internal combustion engine.
One advantage of the mechanical coupling is that the expander
energy does not always have to be permanently available. If the WHR
system is active, the additional mechanical energy of the expansion
machine leads to a reduction in the fuel consumption; if the system
is not ready for operation, the internal combustion engine
compensates for this missing energy.
However, a mechanical utilization concept of the expander energy
results in an attachment of the expansion machine that is dependent
on the engine with regard to rotational speed and positioning. This
leads to it being absolutely necessary for the expansion machine to
be installed on the internal combustion engine, in order for it to
be possible to introduce the energy into the crankshaft of the
internal combustion engine by way of paths which are as short as
possible. In addition, a fluctuating engine rotational speed also
leads to a fluctuating expander rotational speed, as a result of
which the expansion machine cannot always be operated in an optimum
rotational speed range. This disadvantage can be compensated for or
even overcompensated for by way of the advantage of the short
expander-transmission-internal combustion engine efficiency chain,
since modern transmissions have very high degrees of efficiency.
The disadvantage of the rotational speed fluctuations can also be
reduced by way of the selection of those expander types which have
a very flat characteristic curve in the efficiency/rotational speed
characteristic diagram.
A further disadvantage of the mechanical utilization consists in
that no energy can be buffer-stored. As a result, the WHR system
cannot generate any energy when the internal combustion engine is,
for example, in braking mode. The energy stored in the circuit on
account of the thermal inertia has to be conducted past the
expansion machine and therefore cannot be used in a fruitful
manner.
In principle, working chamber-forming machines (for example, piston
engines) at lower rotational speeds are more suitable for
mechanical coupling via a transmission than fast-rotating
turbomachines (steam turbines), since the transmission can be of
simpler configuration.
SUMMARY OF THE INVENTION
It is an object of one aspect of the invention to combine the
above-described advantages of the known utilization concepts and to
overcome the disadvantages, in particular to provide an option, by
which a waste heat utilization system can be utilized in a more
effective manner.
The concept according to one aspect of the invention relates, in
particular, to an apparatus and a method which, instead of pure
electrical utilization or pure mechanical utilization, make
combined utilization of the recuperated energy of an expansion
machine of a waste heat utilization system possible.
The invention provides an apparatus, preferably for a motor
vehicle, for example a commercial vehicle, in particular a lorry or
an omnibus.
The apparatus comprises, in particular, an internal combustion
engine (for example, petrol, diesel, or gas engine or an engine
that can be driven using an alternative fuel), an expansion
machine, and a generator. The expansion machine and/or the
generator can expediently be installed directly or indirectly on
the internal combustion engine.
The apparatus is distinguished, in particular, by the fact that the
expansion machine and the generator can be operatively connected
both to one another and in each case to the internal combustion
engine, preferably a shaft (for example, crankshaft or power
take-off shaft) or a power take-off of the internal combustion
engine, via a transmission, with the result that selective and
therefore combined electrical utilization and mechanical
utilization of the energy of the expansion machine is made
possible. Within the scope of the invention, the generator can
preferably be operatively connected fixedly and/or non-switchably,
in particular permanently, to the internal combustion engine via
the transmission, with the result that, for example, the operative
connection between the generator and the internal combustion engine
cannot be disconnected and therefore expediently cannot be
established and disconnected selectively. Within the scope of the
invention, it is possible as an alternative or in addition,
however, that the operative connection between the expansion
machine and the internal combustion engine can be established and
disconnected by the transmission.
The transmission can expediently be designed to selectively
establish and to disconnect the operative connection of the
expansion machine to the internal combustion engine, but in
contrast to expediently ensure a fixed and/or non-switchable, in
particular permanent, operative connection between the generator
and the internal combustion engine.
The transmission can have a drive and a switching element. The
drive of the transmission can be, for example, a single-stage or
multiple-stage friction wheel or spur gear stage, expediently
without or with at least one intermediate wheel/gear, for example
integrated into a wheel/gear drive of the internal combustion
engine or arranged separately with respect to the latter. The drive
of the transmission can likewise be configured as an external
flexible drive (for example, chain or belt drive) or can consist of
a combination of different drives.
Expediently in a manner dependent on the type of expansion machine,
the transmission can preferably have, in addition to the drive, at
least one clutch or switching element, by way of which the
connection between the expansion machine and the internal
combustion engine can be disconnected, in order for it not to be
necessary to be coupled to the expansion machine, for example,
during cold starting.
The clutch or switching element of the transmission can expediently
be active (for example, electrically or hydraulically actuated
multiple disc clutch, switchable freewheel, etc.) or passive (for
example, clamping body freewheel). The active embodiment preferably
comprises an electrical or hydraulic actuator.
Expediently in a manner dependent on the type of expansion machine,
the transmission can preferably have, in addition to the drive, at
least one decoupling element, by way of which the transmission of
torsional vibrations between (the expediently connected components)
expansion machine-internal combustion engine-generator can be
suppressed. The decoupling element of the transmission can be, for
example, a torsionally elastic connection.
The generator can be configured, for example, as a low voltage
generator (for example, 24 V or 48 V) or high voltage generator
(for example, 400 V to 800 V).
The apparatus can comprise, in particular, an engine backpressure
brake system (for example, exhaust flap brake, turbo exhaust flap
brake, exhaust valve brake system, or turbo exhaust valve brake
system).
It is possible that the expansion machine is part of a mobile waste
heat utilization system for converting waste heat of the internal
combustion engine and/or for converting waste heat of the engine
backpressure brake system into utilizable energy, preferably by
steam circuit, for example an ORC process (Organic Rankine Cycle).
The waste heat utilization system, in particular the expansion
machine, therefore serves, in particular, for energy recuperation
from the waste heat of the internal combustion engine.
It is possible that the expansion machine and the generator can be
operatively connected both to one another and in each case to a
shaft of the internal combustion engine via the transmission. The
shaft preferably comprises the crankshaft of the internal
combustion engine.
It is possible that the generator is configured as a
motor/generator, preferably in order to act selectively in an
expediently current-generating manner as a generator or in an
expediently current-consuming manner as a motor, in particular in
order to selectively operate in a current-generating manner in a
generator operating mode and in a current-consuming manner in a
motor operating mode. As an alternative, it is possible that the
generator is configured as a pure generator and therefore
expediently has no motor function.
It is possible that the generator is connected to an expediently
electrical and/or electronic system via an expediently electrical
and/or electronic connection. The generator can be connected to the
system, for example, via at least one electrical and/or electronic
line. It is likewise possible that the system or at least parts
thereof is/are installed directly on the generator.
The system can have, for example, at least one of the following: an
energy store which can be charged by the generator for storing
electrical energy, at least one electrical consumer of a motor
vehicle (for example, power steering pump, coolant pump and/or one
or more actuators), a, for example, DC/DC converter for supplying
an on-board power network of a motor vehicle, an electric motor,
via which energy from the energy store can be converted into
mechanical energy and can be made available to the internal
combustion engine, and/or a control device for controlling the
generator.
The electrical and/or electronic system can be part of an
electrical and/or electronic infrastructure of a hybrid drive
system which is installed in the motor vehicle, for example can be
connected to and/or combined with a hybrid drive system.
The energy store can have, for example, one or more low voltage or
high voltage batteries, for example 24 V, 48 V or 400 V, to 800 V
batteries.
As has been mentioned above, it is possible that the system has an
electric motor, via which energy from the energy store can be made
available to the internal combustion engine. In this case, the
generator is expediently not configured as a motor/generator, but
rather as a pure generator. The electric motor of the system is
preferably a separate component relative to the generator, for
example the electric motor of a hybrid drive system already
installed in the vehicle.
The system, expediently its energy store, can serve, for example,
to make electrical energy available for an on-board power network
of a motor vehicle and/or at least one electrical consumer of a
motor vehicle, for example via a DC/DC converter which can
optionally be integrated into the system. Thus, in particular via
the DC/DC converter, which is preferably integrated into the
system, the electrical energy for the on-board power network and/or
the at least one electrical consumer can also be made available at
a low voltage level (for example, 24 V voltage level) in the case
of relatively high operating voltages of the generator (for
example, 48 V). As a result, the previous 24 V generator can
expediently possibly be dispensed with and, for example, the
components of expansion machine and generator can be installed in
the installation space which becomes free in a manner which is
virtually neutral in terms of installation space.
It is possible that the storage device (for example, 48 V
batteries) replaces the large part of the storage capacity of the
previous 24 V batteries, a residual capacity on a 24 V basis
expediently remaining necessary merely for the starter of the motor
vehicle.
The generator is preferably operatively connected to the internal
combustion engine in a fixed and/or non-switchable manner, for
example such that it cannot be disconnected and/or is
permanent.
The transmission is preferably configured to selectively establish
and to disconnect the operative connection of the expansion machine
to the internal combustion engine. As an alternative or in
addition, the transmission can form a fixed and/or non-switchable
operative connection (for example, such that it cannot be
disconnected and/or is permanent) between the generator and the
internal combustion engine.
Within the scope of one aspect of the invention, there is therefore
preferably an expediently switchable operative connection between
the expansion machine and the internal combustion engine, and in
contrast there is an expediently fixed and/or non-switchable
operative connection (for example, such that it cannot be
disconnected and/or is permanent) between the generator and the
internal combustion engine.
The apparatus can be operated in different operating modes, namely
in particular in an expander mode, a generator mode, and/or a motor
mode.
It is possible that, in an expander mode, the waste heat
utilization system converts waste heat of the internal combustion
engine into utilizable energy and the expansion machine generates
mechanical energy therefrom and makes the mechanical energy
available to the internal combustion engine via the transmission
and/or, during this, the generator expediently acts as a generator
and generates electrical energy from the utilizable energy,
preferably for the system.
It is possible that the internal combustion engine generates drive
energy in the expander mode.
Energy recuperated by way of the waste heat utilization system can
therefore expediently be divided to the internal combustion engine
in the form of mechanical utilization on one side and to the system
in the form of electrical utilization on the other side.
In the generator mode, the waste heat utilization system may not
yet be ready for operation and/or be in a warm-up phase (for
example, cold starting), in which the expansion machine does not
yet generate any mechanical energy. It is possible as an
alternative or in addition that, in the generator mode, the
internal combustion engine is in an overrun and/or braking mode and
the expansion machine still generates utilizable energy on account
of the thermal inertia of the waste heat utilization system despite
the lacking thermal input from the internal combustion engine. The
utilizable energy can be made available to the generator for
conversion into electrical energy and forwarding to the system. As
an alternative or in addition, mechanical energy can be made
available to the generator by the internal combustion engine via
the transmission to convert the said mechanical energy into
electrical energy and to forward it to the system.
It is possible that, in a motor mode, the generator acts as a motor
or the electric motor of the system acts as a motor.
It is possible that, in a motor mode, the expansion machine again
generates mechanical energy or at least begins to do this, and
makes the mechanical energy available to the internal combustion
engine via the transmission. As an alternative or in addition, it
is possible in the motor mode that the generator acts as a motor or
the electric motor of the system acts as a motor and converts
electrical energy which comes from the energy store into mechanical
energy and makes it available to the internal combustion engine via
the transmission.
In particular, in the motor mode, the expansion machine can either
generate no energy, can generate mechanical energy or can at least
begin to generate mechanical energy and make it available to the
internal combustion engine via the transmission.
It is possible that, in a generator mode, the generator acts as a
generator and the expansion machine generates utilizable energy by
the thermal input from the engine backpressure brake system, but
preferably without the thermal input from the internal engine
combustion of the internal combustion engine, and the utilizable
energy is stored in the energy store and is made available to the
internal combustion engine, for example, in a subsequent motor
mode. It is to be mentioned that the thermal input from the engine
backpressure brake system expediently takes place indirectly via
the waste heat utilization system into the expansion machine.
As a result, it is possible, in particular, that the thermal input
from the internal combustion engine can come either from the
internal engine combustion or the engine backpressure brake
system.
The generator or the electric motor of the system can preferably
act as a motor in the motor mode until the energy store is at least
largely emptied (for example, apart from the minimum permitted
charging state of the battery) and the generator transfers into a
generator mode again.
The internal combustion engine can be configured as a diesel
engine, petrol engine, or gas engine, for example for stationary or
mobile (for example, on-road, off-road or marine) applications. The
internal combustion engine can likewise be capable of operation
using alternative fuels.
It is to be mentioned that the expansion machine and/or the
generator can be installed directly or indirectly on the internal
combustion engine.
Moreover, it is to be mentioned that the energy flow from the
generator and/or the expansion machine to the internal combustion
engine or vice versa preferably takes place via the
transmission.
The invention is not restricted to an apparatus, but rather also
comprises an operating method for an apparatus which is preferably
as described herein.
The invention relates, in particular, to an operating method for
and/or configured by way of an apparatus having an internal
combustion engine, an expansion machine and a generator, it being
possible for the expansion machine and the generator to be
operatively connected both to one another and in each case to the
internal combustion engine via a transmission, and it being
possible for selective and therefore combined electrical
utilization and mechanical utilization of the energy of the
expansion machine to take place. Within the scope of the invention,
the generator can preferably be operatively connected to the
internal combustion engine via the transmission in a fixed and/or
non-switchable, in particular permanent, manner, with the result
that, for example, the operative connection between the generator
and the internal combustion engine cannot be disconnected and
therefore expediently cannot be selectively established and
disconnected. Within the scope one aspect of of the invention, it
is possible as an alternative or in addition, however, that the
operative connection between the expansion machine and the internal
combustion engine can be established and disconnected by means of
the transmission.
Further method steps result from the disclosure in respect of the
apparatus, to which reference is made in order to avoid
repetitions.
The disclosure and description made herein in respect of the
apparatus also applies analogously to the operating method and can
likewise expediently be claimed to this extent.
Other objects and features of the present invention will become
apparent from the following detailed description considered in
conjunction with the accompanying drawings. It is to be understood,
however, that the drawings are designed solely for purposes of
illustration and not as a definition of the limits of the
invention, for which reference should be made to the appended
claims. It should be further understood that the drawings are not
necessarily drawn to scale and that, unless otherwise indicated,
they are merely intended to conceptually illustrate the structures
and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-described embodiments and features of the invention can
be combined with one another. Other advantageous developments of
the invention are disclosed in the subclaims or result from the
following description of preferred embodiments of the invention in
conjunction with the appended figures, in which:
FIG. 1 is an apparatus according to one embodiment of the
invention,
FIG. 2 is the apparatus from FIG. 1 in an expander mode,
FIG. 3 is the apparatus from FIG. 1 in a generator mode, and
FIG. 4 is the apparatus from FIG. 1 in a motor mode.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
The concept according to the invention relates to an apparatus and
a method which, instead of pure electrical or pure mechanical
utilization, make a combined utilization variant of the recuperated
expander energy possible.
An apparatus V for combined or selective electrical and mechanical
utilization of the energy of an expansion machine 3 is shown in
FIG. 1 and is suitable, in particular, for installation in a motor
vehicle, expediently commercial vehicle, for example lorry or
omnibus.
The apparatus V comprises an internal combustion engine 1 which can
preferably be a diesel, petrol, or gas engine for stationary or
mobile (on-road, off-road, or marine) applications, or an engine
using alternative fuels for the said areas of application. The
expansion machine 3 and a motor/generator 4 are installed directly
or indirectly on the internal combustion engine 1.
The expansion machine 3 is part of a waste heat utilization system
that converts waste heat of the internal combustion engine 1 into
utilizable energy again with the aid of a steam circuit, preferably
an ORC process.
The motor/generator 4 can be configured as a low voltage (for
example, 24 V, 48 V) or high voltage generator (for example, 400 V
to 800 V) and, depending on requirements, can operate in a
current-generating manner in the "Generator" operating mode or in a
current-consuming manner in the "Motor" operating mode.
The expansion machine 3 and the generator 4 are operatively
connected both to one another and in each case, in particular, to
the crankshaft of the internal combustion engine 1 via a
transmission 2.
The generator 4 is operatively connected to the internal combustion
engine 1 in a fixed/non-switchable manner, with the result that
there is expediently a permanent operative connection.
In contrast, the expansion machine 3 is operatively connected to
the internal combustion engine 1 such that it can be switched, in
particular disconnected, with the result that an operative
connection can expediently be established and disconnected, in
particular by the transmission 2.
The transmission 2 can consist of a drive and a switching element.
The drive of the transmission 2 can be, for example, a single-stage
or multiple-stage friction wheel or spur gear stage, expediently
without or with at least one intermediate wheel/gear, for example
integrated into a wheel/gear drive of the internal combustion
engine 1 or arranged separately from the latter. The drive of the
transmission 2 can likewise be configured as an external flexible
drive (for example, chain or belt drive) or can consist of a
combination of different drives.
In a manner dependent on the type of expansion machine 3, the
transmission 2 can have, in addition to the drive, at least one
clutch or switching element, by way of which the connection between
the expansion machine 3 and the internal combustion engine 1 can be
disconnected, in order for it not to be necessary to be coupled to
the expansion machine 3, for example, during cold starting. The
clutch or switching element of the transmission 2 can expediently
be active (for example, electrically or hydraulically actuated
multiple disc clutch, switchable freewheel, etc.) or passive (for
example, clamping body freewheel).
In a manner dependent on the type of expansion machine 3, the
transmission 2 can have, in addition to the drive, at least one
decoupling element, by way of which the transmission of torsional
vibrations between the connected components expansion machine
3-internal combustion engine 1-generator 4 can be suppressed. The
decoupling element of the transmission 2 can be, for example, a
torsionally elastic connection.
The motor/generator 4 is connected via an electrical/electronic
connection 5 (for example, line/lines, interface/interfaces, etc.)
to an expediently electrical/electronic system 6 that primarily has
the object of storing electrical energy by an energy store 7 and
controlling the operating mode of the motor/generator 4 by a
control unit. Furthermore, the system 6 can comprise a motor
vehicle on-board power network and/or at least one electrical
consumer of the motor vehicle and/or be an electrical and/or
electronic infrastructure of a hybrid drive system which is
installed in the motor vehicle or can be combined with a hybrid
drive system.
At relatively high operating voltages of the generator 4 (for
example, 48 V), the electrical energy for the on-board power
network and the electrical consumers can also be made available at
the 24 V voltage level via a DC/DC converter which is preferably
integrated into the electrical system 6. As a result, the previous
24 V generator can possibly be dispensed with and the components of
expander 3 and motor/generator 4 can be installed into the free
installation space in a manner virtually neutral in terms of
installation space. In addition, the storage device 7 (for example,
48 V batteries) of the electrical system 6 can replace the large
part of the storage capacity of the previous 24 V batteries; a
residual capacity on a 24 V basis can remain necessary merely for
the starter of the motor vehicle.
As mentioned above, the electrical system 6 can be part of an
electrical and/or electronic infrastructure of a hybrid drive
system which is installed in the motor vehicle, for example can be
replaced by the latter and/or combined with the latter. In this
case, the motor/generator 4 can be configured as a pure generator,
the conversion and introduction of electrical energy preferably
stored in the energy store 7 then taking place via the electric
motor of the hybrid drive system which is already installed in the
motor vehicle.
The apparatus V is configured to be operated in an expander mode, a
generator mode, and a motor mode which can preferably be controlled
via a control unit of the electrical system 6.
The method for combined electrical and mechanical utilization of
the expander energy comprises a plurality of possible operating
states which are controlled via the control unit of the electrical
system 6.
FIG. 2 shows the apparatus V in an expander mode.
The "Expander mode" operating state occurs in that state, in which
the internal combustion engine 1 generates drive energy and the
waste heat utilization system is in operation for waste heat
utilization.
In this operating state, the expansion machine 3 generates
mechanical energy and makes it available to the internal combustion
engine 1 via the transmission 2. During this, the motor/generator 4
operates in the generator mode and generates the required
electrical energy for the system 6, for example the on-board power
network and electrical actuators and/or consumers in the motor
vehicle.
The energy flow in the expander mode is designed substantially as
follows, as depicted in FIG. 2:
Of the 100% energy which is generated by the expansion machine 3, X
% is converted into electrical energy via the motor/generator 4 in
the generator mode and is made available to the electrical system
6. The remaining (100-X) % is available as mechanical energy at the
crankshaft of the internal combustion engine 1 or for the internal
combustion engine 1. The size of the value X is based on the
current power consumption of the motor vehicle.
Advantages over purely electrical or purely mechanical
utilization:
Despite electrical utilization, the electrical energy generated is
independent of the currently generated expander energy, since the
excess flows as mechanical energy to the internal combustion engine
1 in a manner which is optimum in terms of the degree of
efficiency.
FIG. 3 shows the apparatus V in a generator mode.
The "Generator mode" operating state occurs in that state, in which
the waste heat utilization system is not yet ready for operation
and is in the warm-up phase (for example, after cold starting) or
in which the internal combustion engine 1 is in an overrun and/or
braking mode.
In the warm-up phase of the waste heat utilization system, the
expansion machine 3 does not yet generate any mechanical energy.
During this, the motor/generator 4 operates in the generator mode
and generates the necessary electrical energy for the system 6, for
example the on-board power network and the electrical actuators
and/or consumers in the motor vehicle.
In the overrun and/or braking mode of the internal combustion
engine 1, the expansion machine 3 still generates utilizable
energy, on account of the thermal inertia of the waste heat
utilization system, despite the missing thermal input. During this,
the motor/generator 4 operates in the generator mode and generates
the maximum possible electrical energy made available to the energy
store 7 of the system 6.
In the generator mode, it is possible, in particular, that the
expansion machine 3 generates utilizable energy, to be precise by
heat from an engine backpressure brake system, the heat from the
engine backpressure brake system passing indirectly to the
expansion machine 3 via the waste heat utilization system. The
utilizable energy generated can be stored in the energy store 7 and
can be made available to the internal combustion engine 1 in a
subsequent motor mode.
The energy flow in the generator mode is designed substantially as
follows, as depicted in FIG. 3:
Of the 100% energy generated by the motor/generator 4 in the
generator mode, X % comes from the expansion machine 3, and the
remaining (100-X) % is made available by the internal combustion
engine 1 via the transmission 2 which is optimum in terms of the
degree of efficiency. The size of the value X is zero during the
warm-up operation of the waste heat utilization system.
Advantages over purely electrical or purely mechanical
utilization:
In the overrun or braking mode of the internal combustion engine 1,
the energy which is stored in the waste heat utilization system on
account of the thermal inertia does not have to bypass the
expansion machine 3 without being utilized, but rather can be
converted into electrical energy and stored in a fruitful
manner.
In addition, in the overrun and braking mode of the internal
combustion engine 1, energy can preferably be recuperated by way of
the motor/generator 4 and can be charged into the energy store 7 of
the system 6.
Internal combustion engines 1 in the described applications are
often equipped with modern engine braking systems which generate
high, hot gas mass flows through the internal combustion engine 1
in the engine braking mode. In the case of purely electrical or
purely mechanical utilization of the expander energy of the waste
heat utilization system, this is lost to the surroundings via the
exhaust gas system, since the generated expander energy cannot be
exploited in this operating state. In the case of combined
utilization according to the invention, the said heat can be
utilized and can be buffer-stored via the motor/generator 4 and the
system 6 and utilized again in the following drive phase.
FIG. 4 shows the apparatus V in a motor mode.
The "Motor mode" operating state occurs in that state, in which the
waste heat utilization system is in operation or out of operation
and the energy store 7 of the electrical system 6 has been charged
completely or else only partially with the aid of the
motor/generator 4 in a preceding overrun and/or braking mode of the
internal combustion engine 1.
In this operating state, the expansion machine 3 either does not
generate any mechanical energy, it generates mechanical energy or
it begins to generate mechanical energy again by way of the thermal
input into the waste heat utilization system which is again
present, and makes the said mechanical energy available to the
internal combustion engine 1 via the transmission 2.
During this, the motor/generator 4 operates in the motor mode and
also introduces the electrical energy which is removed from the
energy store 7 of the system 6 and is converted into mechanical
energy into the internal combustion engine 1 via the transmission
2.
The on-board power network and the electrical actuators and/or
consumers in the motor vehicle can be supplied by the energy store
7 of the system 6, for example via a DC/DC converter, until the
said energy store 7 is emptied and the motor/generator 4 transfers
into the generator mode again.
The energy flow is designed substantially as follows, as depicted
in FIG. 4:
Of the 100% energy which is made available to the internal
combustion engine 1 via the transmission 2, X % comes from the
expansion machine 3 and the remaining (100-X) % comes from the
motor/generator 4 which uses the energy in the energy store 7 of
the system 6. If insufficient energy from the waste heat
utilization system is available to the expansion machine 3, the
size of the value X is zero.
Advantages over purely electrical or purely mechanical
utilization:
In the fired mode of the internal combustion engine 1, which
follows an overrun and/or braking phase of the internal combustion
engine 1, no energy from the expander 3 is directly available,
since the waste heat utilization system first of all has to warm up
again. Precisely in these fuel-intensive operating states, the
energy recuperated and stored in the overrun and/or braking mode of
the internal combustion engine 1 can be made available directly to
the internal combustion engine 1 via the motor/generator 4 in a
manner that reduces the consumption.
It is to be mentioned that the generator 4 does not have to be
configured as a motor/generator, but rather can also be configured
as a pure generator. In this case, the system 6 can have an
electric motor which can assume the motor function of the
motor/generator 4.
The system 6 and the electric motor can be part here of a hybrid
drive system which is already installed in the motor vehicle.
The invention is not restricted to the above-described preferred
embodiments. Rather, a multiplicity of variants and modifications
are possible which likewise use the concept of the invention and
therefore fall within the scope of protection. Moreover, the
invention also claims protection for the subject matter and the
features of the subclaims independently of the features and claims
referred to.
Thus, while there have shown and described and pointed out
fundamental novel features of the invention as applied to a
preferred embodiment thereof, it will be understood that various
omissions and substitutions and changes in the form and details of
the devices illustrated, and in their operation, may be made by
those skilled in the art without departing from the spirit of the
invention. For example, it is expressly intended that all
combinations of those elements and/or method steps which perform
substantially the same function in substantially the same way to
achieve the same results are within the scope of the invention.
Moreover, it should be recognized that structures and/or elements
and/or method steps shown and/or described in connection with any
disclosed form or embodiment of the invention may be incorporated
in any other disclosed or described or suggested form or embodiment
as a general matter of design choice. It is the intention,
therefore, to be limited only as indicated by the scope of the
claims appended hereto.
* * * * *